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Complex equipment replacement project in Fort McMurray highlights the importance of planning, specialized lifting equipment and concrete-intensive foundations in industrial construction.
Mammoet used its PTC210DS ring crane for its lifting capacity and reach to successfully replace eight coke drums at a major Canadian oil sands operation in Fort McMurray. Im age courtesy of Mammoet.
Replacing eight coke drums at a major Canadian oil sands operation in Fort McMurray has been completed ahead of schedule, demonstrating the critical role of planning, coordination and the right equipment in complex industrial projects. The Base Plant site upgraders, which convert bitumen into synthetic crude using coking and hydrotreating processes, rely on coke drums to gather petroleum coke separated during refining. Each drum weighs 270 tonnes, stands nearly 30 metres tall and measures almost 8 metres in diameter, making precise handling and installation essential for safety and efficiency.
Mammoet, a specialist in heavy lifting and transport solutions, was involved from the early planning stages, conducting feasibility analyses and equipment assessments to determine the optimal approach for removing the original drums and installing the replacements. Engineers reviewed multiple crane options, ultimately selecting a PTC210DS ring crane for its lifting capacity and reach, allowing operations to continue safely around the work zone. Civil works, including the installation of approximately 200 piles, were carried out to support the crane inside the coke pit.
Logistics and modular handling streamline execution
The project required careful coordination of logistics, beginning 18 months prior to the scheduled plant shutdown. Components were transported from Edmonton to Fort McMurray via prime movers on public roads and Self-Propelled Modular Transporters (SPMTs) on site. By staging equipment, materials and modules well in advance, project teams minimized downtime during the shutdown window.
On site, two shifts of SPMT crews kept operations moving continuously, feeding components to the PTC crane for installation. The process involved dismantling the old derricks and drums, moving them to laydown areas for decommissioning and assembling the new supermodules on site. The largest derrick modules required specialized rigging and a double masthead crane configuration to achieve the necessary lifts.
Concrete-intensive foundations support industrial lifts
The installation of coke drums and associated supermodules relied heavily on concrete-intensive foundations. These base sections provide the stability required for both the massive weight of the drums and the precision placement needed for ongoing operations. By combining detailed planning with robust concrete work, the project team ensured that critical lifting operations could proceed without interruption, reducing risks and maximizing schedule adherence.
Efficiency and safety at the forefront
This particular project highlights the value of early involvement, rigorous planning and specialized equipment in large-scale industrial construction. Production at the site continued up until the day before the planned shutdown, reflecting careful sequencing and collaboration among engineers, riggers and operators. For contractors engaged in concrete-intensive or heavy civil work, the Fort McMurray project illustrates how disciplined project management and technical expertise contribute to on-time, safe and cost-effective outcomes.